Engine Cooling System: Radiator: Reassembly

INSTALL LOWER RADIATOR TANK
1. After checking that there are no foreign objects in the lock plate groove, install a new O-ring without twisting it.
  HINT:
  
  When cleaning the lock plate groove, lightly rub it with sandpaper without scratching it.
  
  Fig 1: Installing Lower Radiator Tank
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Tap the lock plate with a plastic-faced hammer so that there is no gap between the lock plate and the tank.
  NOTE: Do not tap the areas protruding around the pipes, brackets or tank ribs.
  
  Fig 2: Tapping Lock Plate
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Install the punch assembly to the overhaul handle, inserting it in the hole in part A as shown in the illustration.
  SST 09230-01010 (09231-01010, 09231-01020), 09231-14010
4. While gripping the handle, adjust the stopper bolt so that dimension B is as specified below.
  Dimension B:
  
  8.8 mm (0.347 in.)
  
  Fig 3: Adjusting Stopper Bolt - Dimension B
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Lightly press SST against the lock plate in the order shown in the illustration. After repeating this procedure a few times, fully crimp the lock plate by squeezing the handle until stopped by the stopper bolt.
  SST 09230-01010 (09231-01010, 09231-01020), 09231-14010
  
  Fig 4: Identifying Lock Plate With Squeezing Handle
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Do not crimp the protruding areas around ports A and brackets B.
    
    Fig 5: Identifying Crimp Protruding Areas Around Ports A And Brackets B
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - Do not use SST to crimp the circled areas indicated in the illustration. Use pliers and be careful not to damage the core plates.
    
    Fig 6: Locating Core Plate
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Check the lock plate height A after completing the crimping.
  Standard plate height A:
  
  8.8 mm (0.347 in.)
  
  If the height is not as specified, readjust the stopper bolt of the handle and crimp the lock plate again.
INSTALL UPPER RADIATOR TANK
HINT:

The installation procedure for the upper radiator tank is the same as that for the lower radiator tank.

Fig 7: Identifying Lock Plate Height
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL DRAIN PLUG
1. Install a new O-ring to the drain plug.
2. Install a new O-ring to the air drain plug.
3. Install the drain plug and air drain plug.
INSPECT FOR WATER LEAK
1. Plug the inlet and outlet pipes of the radiator with SST.
  SST 09230-01010 (09231-00030, 09231-00060)
2. Using a radiator cap tester, apply pressure to the radiator.
  Standard test pressure:
  
  177 kPa (1.8 kgf/cm ² , 26 psi)
3. Submerge the radiator in water.
4. Inspect for leak.
  HINT:
  
  On radiators with resin tanks, there is clearance between the tank and lock plate where a minute amount of air will remain, giving the appearance of an air leak when the radiator is submerged in water. Therefore, before doing the water leak test, first swish the radiator around in the water until all air bubbles disappear.
  
  Fig 9: Inspecting For Leakage
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSTALL RADIATOR WATER INLET
1. Install the radiator water inlet with the 2 bolts.
  Torque: 7.1 N*m (72 kgf*cm, 63 in.*lbf)
  
  Fig 10: Installing Radiator Water Inlet With Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002